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CBR954RR 2002
Service manual
Table Of Contents - Honda CBR954RR 2002 Service Manual
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Service manual
(495 pages)
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Table Of Contents
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
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Table of Contents
Contents
2
How To Use This Manual
2
Symbols
3
General Information
4
Service Rules
4
Model Identification
4
Vehicle Identification Number (Vin)
5
Throttle Body Id~Ntification Number
5
Color Label
5
Specifications
6
Cylinder Headnalves
9
Torque Values
15
Note
15
Frame
18
Tools
20
Lubrication & Seal Points
22
Cable & Harness Routing
26
Emission Control Systems
40
Source Of Emissions
40
Crankcase Emission Control System
40
Exhaust Emission Control System (Secondary Air Supply System)
41
Evaporative Emission Control System (California Type Only)
42
Emission Control Information Labels
43
Vacuum Hose Routing Diagram Label
43
Body Panel Locations
44
Frame/Body Panel/Exhaust System Service Information
45
Frame/Body Panel/Exhaust System Troubleshooting
45
Frame/Body Panel/Exhaust System Torque Values
45
Seat Removal
46
Seat Installation
46
Pillion Seat/Rear Cowl Removal
46
Pillion Seat/Rear Cowl Installation
47
Duct Cover Removal/Installation
48
Upper Cowl Removal
49
Upper Cowl Installation
50
Lower Cowl Removal/Installation
51
Middle Cowl Removal/Installation
51
Windscreen Removal/Installation
52
Front Fender Removal
52
Front Fender Installation
52
Rear Fender Removal/Installation
53
Rear Fender Removal
53
Rear Fender Installation
55
Seat Rail Removal
55
Seat Rail Installation
56
Muffler/Exhaust Pipe Removal
57
Maintenance
64
Maintenance Schedule
66
Fuel Line
67
Throttle Operation
68
Air Cleaner
69
Spark Plugs Removal
69
Spark Plugs Inspection
71
Valve Clearance Inspection
73
Oil Level Inspection
78
Engine Idle Speed
80
Radiator Coolant
81
Cooling System
81
Secondary Air Supply System
82
Evaporative Emission Control System
82
Drive Chain Slack Inspection
83
Drive Chain Adjustment
83
Drive Chain Cleaning And Lubrication
84
Drive Chain Sprockets Inspection
84
Drive Chain Replacement
85
Brake Fluid
87
Front Brake
87
Rear Brake
87
Brake Pad Wear
88
Brake System Inspection
88
Front Brake Pads
88
Rear Brake Pads
88
Brake Light Switch
89
Brake Lever Adjustment
89
Brake Pedal Height Adjustment
89
Headlight Aim
90
Clutch System
90
Side Stand
91
Front Suspension Adjustment
91
Front Suspension Inspection
91
Compression And Rebound Damping Adjusters
92
Compression Adjuster Standard Position
92
Rebound Adjuster Standard Position
92
Rear Suspension Inspection
92
Rear Suspension Adjustment
93
Nuts, Bolts, Fasteners
94
Wheels/Tires
94
Recommended Tire Pressure And Tire Size
94
Minimum Tread Depth
94
Steering Head Bearings
95
Lubrication System Diagram
96
Lubrication System Service Information
97
Lubrication System Specifications
97
Lubrication System Troubleshooting
98
Lubrication System Torque Values
98
Lubrication System Tools
98
Oil Pressure Inspection
99
Oil Strainer/Pressure Relief Valve Removal
99
Oil Strainer/Pressure Relief Valve Inspection
100
Oil Strainer/Pressure Relief Valve Installation
100
Oil Pump Removal
101
Oil Pump Disassembly
102
Oil Pump Inspection
102
Oil Pump Assembly
103
Oil Pump Installation
104
Oil Cooler Removal
105
Oil Cooler Inspection
105
Oil Cooler Installation
106
Fuel System (Programmed Fuel Injection)
108
Fuel System (Programmed Fuel Injection) Service Information
109
Fuel System (Programmed Fuel Injection) Specifications
110
Fuel System (Programmed Fuel Injection) Troubleshooting
111
Fuel System (Programmed Fuel Injection) Torque Values
111
Fuel System (Programmed Fuel Injection) Tools
111
Fuel System (Programmed Fuel Injection) Location
112
Fuel System (Programmed Fuel Injection) Diagram
113
Pgm-Fi (Programmed Fuel Injection) System
114
Self-Diagnostic Procedures
114
Self-Diagnosis Reset Procedure
115
Peak Voltage Inspection Procedure
116
Test Harness Connection
116
Test Harness Terminal Layout
117
Pgm-Fi Self-Diagnosis Malfunction Indicator Lamp (Mil) Failure Codes
118
Pgm-Fi Mil 1 Blink (Map Sensor)
120
Pgm-Fi Mil 2 Blinks (Map Sensor)
122
Pgm-Fi Mil 7 Blinks (Ect Sensor)
124
Pgm-Fi Mil 8 Blinks (Tp Sensor)
126
Fuel System
127
Pgm-Fi Mil 9 Blinks (Iat Sensor)
130
Pgm-Fi Mil 11 Blinks (Vehicle Speed Sensor)
132
Pgm-Fi Mil 12 Blinks (No.1 Injector)
134
Pgm-Fi Mil 13 Blinks (No.2 Injector)
137
Pgm-Fi Mil 14 Blinks (No.3 Injector)
140
Pgm-Fi Mil 15 Blinks (No.4 Injector)
143
Pgm-Fi Mil 18 Blinks (Cam Pulse Generator)
146
Pgm-Fi Mil 19 Blinks (Ignition Pulse Generator)
148
Pgm-Fi 21 Blinks
150
Pgm-Fi Mil 23 Blinks
152
Pgm-Fi Mil 33 Blinks (E2-Prom)
156
Pgm-Fi Mil 34 Blinks (Egcv And Air Intake Valve Servo Motor Voltage)
158
Pgm-Fi Mil 35 Blinks (Egcv And Air Intake Valve Servo Motqr)
160
Fuel Pressure Inspection
162
Fuel Flow Inspection
164
Fuel Pump Inspection
165
Fuel Pump Removal
165
Fuel Filter Replacement
166
Fel Pump Installation
166
Fuel Cut-Off Relay
166
Fuel Tank Removal
167
Fuel Tank Installation
169
Air Cleaner Housing Removal
172
Air Cleaner Housing Installation
173
Throttle Body Removal
175
Rear View
177
Throttle Drum View
177
Right Side View
177
Throttle Link View
177
Throttle Body Vacuum Hose Routing
178
Injectors Inspection
180
Injectors Removal
180
Injectors Installation
181
Pressure Regulator Removal/Installation
182
Fast Idle Wax Unit Removal
183
Fast Idle Wax Unit Installation
183
Starter Valve Disassembly
184
Starter Valve Assembly
185
Starter Valve Synchronization
187
Hydraulic Brake
189
Brake Pad/Disc
190
Front Brake Pad Replacement
190
Rear Brake Pad Replacement
192
Brake Disc Inspection
193
Front Master Cylinder Removal
194
Front Master Cylinder Disassembly
194
Front Master Cylinder Inspection
196
Front Master Cylinder Assembly
196
Rear Master Cylinder Removal
199
Rear Master Cylinder Disassembly
200
Rear Master Cylinder Inspection
201
Rear Master Cylinder Assembly
201
Rear Master Cylinder Installation
203
Front Brake Caliper Removal
203
Rear Brake Caliper Removal
207
Rear Brake Caliper Disassembly
207
Rear Brake Caliper Inspection
208
Rear Brake Caliper Assembly
209
Rear Brake Caliper Installation
210
Brake Pedal Removal
210
Brake Pedal Installation
211
Battery/Charging System Diagram
213
Battery/Charging System Service Information
214
Battery/Charging System Specifications
215
Battery Testing
215
Battery/Charging System Troubleshooting
216
Battery Is Damaged Or Weak
216
Battery Removal/Installation
217
Voltage Inspection
217
Battery Charging
218
Charging System Inspection
219
Current Leakage Inspection
219
Charging Voltage Inspection
219
Alternator Charging Coil Inspection
220
Regulator/Rectifier System Inspection
220
Ignition System
222
Ignition System Service Information
223
Ignition System Specifications
223
Ignition Pulse Generator
223
Ignition System Torque Values
224
Ignition System Tools
224
Ignition System Troubleshooting
225
Ignition System Inspection
226
Ignition Coil Primary Peak Voltage
226
Ignition Pulse Generator Peak Voltage
227
Ignition Pulse Generator Removal
228
Ignition Pulse Generator Installation
229
Ignition Timing
230
Electric Starter System Diagram
232
Electric Starter Service Information
233
Electric Starter Specification
233
Electric Starter Torque Value
233
Electric Starter Troubleshooting
234
Starter Motor Does Not Turn
234
Starter Motor Turns Engine Slowly
235
Starter Motor Turns, But Engine Does Not Turn
235
Starter Relay Switch "Clicks", But Engine Does Not Turn Over
235
Starter Motor Removal
236
Starter Motor Disassembly
236
Starter Motor Inspection
237
Starter Motor Assembly
239
Starter Motor Installation
241
Starter Relay Switch Operation Inspection
242
Starter Relay Switch Ground Line Inspection
242
Starter Relay Voltage Inspection
243
Continuity Inspection
243
Diode Removal
243
Diode Inspection
243
Lights/Meter/Switches System Location
244
Lights/Meter/Switches Service Information
245
Lights/Meter/Switches Specifications
246
Lights/Meter/Switches Torque Values
246
Lights/Meter/Switches Tools
246
Lights/Meter/Switches Troubleshooting
247
Speed Sensor/Speedometer
247
Headlight Bulb Replacement
248
Headlight Removal/Installation
249
Turn Signal Bulb Replacement
250
Brake/Tail Light Inspection
250
Brake/Tail Light Removal/Installation
250
License Light Bulb Replacement
251
Combination Meter Removal
251
Speedometer/Vehicle Speed Sensor Voltage Inspection
253
Output Signal Inspection
254
Tachometer Inspection
256
Ect/Thermo Sensor Inspection
256
Oil Pressure Switch Inspection
258
Oil Pressure Switch Removal/Installation
258
Fuel Reserve Sensor Inspection
259
Ignition Switch Inspection
260
Ignition Switch Removal/Installation
260
Handlebar Switches
261
Clutch Switch
262
Neutral Switch
262
Side Stand Switch Inspection
263
Side Stand Switch Removal
263
Side Stand Switch Installation
264
Horn
264
Turn Signal Relay
265
Troubleshooting
266
Engine Does Not Start Or Is Hard To Start
266
Engine Lacks Power
267
Poor Performance At Low And Idle Speed
268
Poor Performance At High Speed
269
Poor Handling
269
Index
270
Table Of Contents
270
Wiring Diagram
272
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Table of Contents
Troubleshooting
Frame/Body Panel/Exhaust system Service Information
45
Lubrication System Troubleshooting
98
Fuel System (Programmed Fuel Injection) Troubleshooting
111
Battery/charging system troubleshooting
216
Ignition system troubleshooting
225
Electric starter troubleshooting
234
Lights/Meter/Switches Troubleshooting
247
Troubleshooting
266
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